Arrangement for a movable roof element for a motor vehicle and system for a motor vehicle

ABSTRACT

An arrangement for a movable roof element ( 101 ) for a motor vehicle ( 100 ) has:
         a carriage ( 103 ) which is designed to be guided in a rail ( 104 ) and to be moved relative to the rail ( 104 ) and which has a first component ( 105 ) and a second component ( 106 ), and   a drive cable ( 107 ), wherein the second component ( 106 ) at least partially surrounds the first component ( 105 ) and the drive cable ( 107 ) in order to form a coupling ( 108 ) between the drive cable ( 107 ) and the carriage ( 103 ), wherein the coupling ( 108 ) has:   a roughening ( 109 ) of the first component ( 105 ) in order to form a non-positive and/or integrally bonded connection between the first ( 105 ) and the second ( 106 ) component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national phase application filed under 35U.S.C. § 371 of International Application No. PCT/EP2016/068789, filedAug. 5, 2016, designating the United States, which claims priority fromGerman Patent Application 10 2015 115 285.1, filed Sep. 10, 2015, whichare hereby incorporated herein by reference in their entirety for allpurposes.

FIELD

The invention relates to an arrangement for a movable roof element for amotor vehicle, in particular for a cover which is able to close a roofopening. The invention further relates to a system for a movable roofelement for a motor vehicle which comprises such an arrangement.

BACKGROUND

Roofs for motor vehicles may be provided with a sliding roof. A roofelement, also called a cover, in this case is either able to close aroof opening in a closed position of the cover or at least partiallyopen said roof opening in further positions. For controlling themovement of the roof element, a raising mechanism is provided. Theraising mechanism is coupled firstly to the roof element and secondly toa carriage. The carriage is guided in a rail which is arranged in thevehicle roof.

In the event of an accident, in particular in the event of a frontimpact, i.e. a collision with an obstruction in the direction of travel,it is possible that the roof element is accelerated to such an extentthat the coupling between the roof element and the guide rail is tooweak in order to retain the roof element. The roof element may bereleased, therefore, from the vehicle roof. To prevent such anacceleration of the roof element, safety brake devices are disclosed,for example, in EP 1 905 631 A1. These safety brake devices are attachedto the carriage and jam the carriage to the rail in the event of anabrupt acceleration of the roof element.

It is desirable to specify an arrangement for a movable roof element aswell as a system for a movable roof element which permits a reliablecoupling of the roof element to a rail, in particular even in the eventof an accident. For example, it is desirable to permit a reliablecoupling as an alternative or in addition to a safety brake device.

SUMMARY

According to one aspect of the invention, an arrangement for a movableroof element for a motor vehicle has a carriage. The carriage isdesigned to be guided in a rail and to be moved relative to the rail.The carriage has a first component and a second component. Thearrangement has a drive cable. The second component at least partiallysurrounds the first component and the drive cable in order to form acoupling between the drive cable and the carriage. According to oneaspect of the invention, the coupling has a roughening of the firstcomponent in order to form a non-positive and/or integrally bondedconnection between the first and the second component. In particular,the roughening is produced by a laser, for example by the action of alaser beam on the first component.

The first component comprises the roughening which is provided, inparticular, in a region of the drive cable. A surface of the firstcomponent is roughened. Thus the first component and the secondcomponent are connected together by a non-positive and/or integrallybonded connection, for example in the manner of an adhesive bond. Thusthe risk of a detachment of the second component from the firstcomponent is reduced. Thus greater forces may be transmitted from thefirst component to the second component and thus to the drive cable thanmight be the case without the roughening. In the event of an accident,therefore, it is possible to slow down the acceleration of the roofelement sufficiently by means of the coupling of the roof element to thecarriage and the coupling of the carriage to the drive cable, in orderto prevent a decoupling of the roof element from the vehicle. The drivecable is used as a brake for the roof element. By the roughening of thesecond component, the coupling between the carriage and the drive cableis sufficiently stable in order to absorb the forces which are presenthere.

According to a second aspect of the invention, an arrangement for amovable roof element for a motor vehicle has a carriage which isdesigned to be guided in a rail and to be moved relative to the rail.The carriage has a first component and a second component. Thearrangement has a drive cable. The second component at least partiallysurrounds the first component and the drive cable in order to form acoupling between the drive cable and the carriage. The couplingaccording to the second aspect has a recess of the first component. Amaterial of the second component is arranged in the recess. The couplinghas a retaining head which is configured by means of the secondcomponent on a side remote from the drive cable in a region of therecess.

By means of the recess in the second component it is possible to arrangethe material of the second component on the first component such thatthe retaining head is formed on the side remote from the drive cable.Starting with the retaining head, the second component extends throughthe recess to the drive cable and surrounds the drive cable. Theretaining head is configured to be wider than the recess and thusretains the drive cable on the first component in the manner of awelding dome and/or a plastics rivet. Thus the drive cable is fastenedsufficiently firmly to the carriage by means of the coupling in order toabsorb the forces present in the event of an accident. The couplingbetween the drive cable and the carriage is sufficiently stable for thedrive cable to slow down the acceleration of the roof element in theevent of an accident. A detachment of the drive cable from the carriageis preventable by the retaining head, which is formed from the secondcomponent, and the arrangement of the second component in the recess.The coupling is sufficiently strong to transmit the forces reliably fromthe roof element to the drive cable. The drive cable is used as a brakefor the roof element.

By means of the coupling according to the first aspect and the couplingaccording to the second aspect, in each case the drive cable and thecarriage are connected sufficiently firmly together in order to preventa detachment of the carriage from the drive cable in the event of anaccident. The coupling according to the first aspect and the couplingaccording to the second aspect in each case are sufficiently stable inorder to withstand and to transmit the forces which act on the couplingin the event of an accident. By means of the coupling according to thefirst aspect and the coupling according to the second aspect, in eachcase reliable connections are made between the drive cable and thecarriage, which as an alternative or in addition to a safety brakedevice prevent an uncontrolled acceleration of the roof element.

Further embodiments comprise a combination of the first aspect and thesecond aspect. The coupling comprises, therefore, the recess of thefirst component and the retaining head. Moreover, the coupling comprisesthe roughening of the first component in order to form a non-positiveand/or integrally bonded connection between the first and the secondcomponent. Thus it is possible to transmit greater forces between thedrive cable and the carriage than respectively in the first aspect andthe second aspect alone.

According to further embodiments, the coupling comprises a retainingelement. The retaining element is connected to the drive cable. Theretaining element, starting from the drive cable, extends through therecess. In particular, the retaining element forms a positive connectionwith the second component. The retaining element is, in particular,extended longitudinally along the drive cable. Thus, by means of theretaining element it is possible to reduce or to prevent the carriageand/or the second component from rotating and/or deflecting. As aresult, it is possible to prevent a detachment of the second componentfrom the first component, which has been caused by the rotation. As aresult, the coupling between the carriage and the drive cable is able totransmit high forces.

According to further embodiments, the retaining element comprises aprojecting region which projects over the first component on the sideremote from the drive cable. Thus it is possible for the retainingelement to be hooked behind the first component. As a result, it isprevented that the retaining element is inadvertently removed from therecess.

According to further embodiments, the retaining element is formed from ametal, in particular a sheet metal part. The retaining element isattached, in particular, to the drive cable by means of a plasticdeformation of the retaining element. For example, the retaining elementis crimped onto the drive cable.

According to further embodiments, the first component is formed from ametal, for example steel. The second component is formed from a plasticsmaterial. For example, the coupling is formed by encapsulating the drivecable and the first component by injection-molding with the plasticsmaterial. Thus an integrally bonded connection is made between thecarriage and the drive cable. A plug connection between the carriage andthe drive cable may be dispensed with.

According to a third aspect of the invention, a system for a movableroof element for a motor vehicle comprises an arrangement according toan embodiment as disclosed above. The system comprises the rail. Therail comprises a guide channel. The carriage is guidable in the guidechannel. The carriage has a predetermined cross section. The crosssection is predetermined such that the carriage is guidable in the guidechannel irrespective of the type of coupling. The rail comprises thesame cross section, irrespective of whether the coupling is formedaccording to the first aspect or according to the second aspect or acombination or development thereof. The system is, therefore, able to beconfigured in a modular manner in the same constructional spaceaccording to the first aspect or the second aspect or the combinationthereof. In particular, the requirement for constructional space is thesame as in conventional systems.

BRIEF DESCRIPTIONS OF THE DRAWINGS

Further advantages, features and embodiments are disclosed from thefollowing examples described in connection with the figures, in which:

FIG. 1 shows a schematic view of an embodiment of a vehicle,

FIG. 2 shows a schematic view of an embodiment of an arrangement,

FIG. 3 shows a schematic view of a cross section of an embodiment of asystem,

FIG. 4 shows a schematic view of an embodiment of an arrangement,

FIG. 5 shows a schematic view of an embodiment of an arrangement,

FIG. 6 shows a schematic view of an embodiment of an arrangement and

FIG. 7 shows a schematic view of an embodiment of an arrangement.

DETAILED DESCRIPTION

In the exemplary embodiments and figures, elements which are the same,similar or have the same function may be provided in each case with thesame reference numerals.

FIG. 1 shows a detail of a motor vehicle 100. The motor vehicle 100comprises a vehicle roof 120. A front windshield 122 is arranged in thenormal operating position at the front. A rear windshield 123 isarranged in the X-direction to the rear. The vehicle roof 120 extends,in particular, between the front windshield 122 and the rear windshield123. The vehicle roof 120 comprises a roof opening 121. The roof opening121 is closable by a roof element 101. By a movement of the roof element101 relative to the remaining vehicle roof 120, the roof opening 121 isable to be at least partially opened. The roof element 101 is, forexample, part of a panoramic sunroof, a spoiler roof, a sliding roof,for example an externally guided sliding roof, and/or a sliding-liftingroof, a roof which is able to be mounted from the top (top-load) or aroof which is able to be mounted from the bottom (bottom-load). The roofelement 101 is also called a cover and is made, for example, from glassor a transparent plastics material.

The roof element 101 is provided with a raising mechanism (notexplicitly shown). The raising mechanism is in turn coupled to acarriage 103 (FIGS. 2 to 6). The carriage 103 is part of a system 300.The system 300 comprises a rail 104 which is coupled to the vehicle roof120. Additionally, a drive cable 107 which is at least partially guidedin the guide rail 104 and is connected to the carriage 103 is provided.The drive cable and the carriage 103 are both encapsulated byinjection-molding. In the Y-direction of FIG. 1, on both sides of theroof element 101 the system 300 comprises the guide rail 104, the drivecable 107 and the carriage 103. These components are configured on bothsides, in each case corresponding to one another, so that hereinafteronly one side of the system 300 is described. The descriptions applyequally to the other side of the system 300.

A motor 102 is provided, in particular an electric motor, in order tomove the drive cable 107 relative to the guide rail 103. The electricmotor 102 may also be arranged [on] the side of the roof opening 121facing the front windshield 122, as shown in FIG. 1. The motor 102 isarranged at a different position, according to further exemplaryembodiments, for example on a side of the roof opening 121 facing therear windshield 123.

FIG. 2 shows an arrangement 200 which comprises the carriage 103 and thedrive cable 107. The drive cable 107 is connected to the carriage 103 bymeans of a coupling. In particular, the drive cable 107 isinjection-molded on the carriage so that the drive cable 107 and thecarriage 103 are configured integrally.

The drive cable 107 is configured to transmit both pulling and pushingforces to the carriage 103. In particular, the drive cable 107 isdesigned to be rigid in compression. According to further embodiments,two or more drive cables are provided. The drive cable 107 comprises ahelical outer face in order to transmit a drive force of a gearwheel ofthe motor 120 to the carriage 103.

FIG. 3 shows an embodiment of the system 300. The carriage 103 is guidedin a guide channel 116 of the rail 104.

The carriage 103 comprises a first component 105. The first component105 is formed from a metal, for example from steel. The carriage 103comprises a second component 106. The second component 106 is formedfrom a plastics material and, for example, is applied to the firstcomponent 105 by means of a method of encapsulation byinjection-molding. The drive cable 107 is also injection-molded to thefirst component 105 by means of the second component 106. The secondcomponent 106 thus connects the drive cable 107 to the carriage 103, inparticular to the first component 105 of the carriage 103.

A coupling 108 is configured in order to couple the drive cable 107 bymeans of the carriage 103 to the roof element 101. The coupling 108 isconfigured to be sufficiently stable in order to remain stable even inthe case of forces which in the event of an accident, in particular afront impact, accelerate the roof element in the negative X-direction inthe direction of the front windshield 122. The coupling 108 isconfigured such that a separation is prevented between the drive cable107 and the carriage 103. In particular, a detachment of the secondcomponent 106 from the first component 105 is prevented in the region ofthe coupling 108 between the drive cable 107 and the first component105.

FIG. 4 shows the arrangement 200 with the coupling 108 according to afirst aspect. The coupling 108 comprises a roughening 109 of the firstcomponent 105. The roughening 109 is incorporated on at least one side117 of the first component 105 facing the drive cable 107. For example,the first component 105 is roughened by the action of a laser beam.Moreover, other methods for roughening the surface of the firstcomponent 105 are possible, for example a mechanical treatment forforming the roughening 109.

By means of the roughening 109 of the surface of the steel of the firstcomponent 105, a non-positive connection of the second component 106 tothe first component 105 is made at least in the region of the roughening109. Due to the roughening 109 on the surface of the first component 105a microstructure is formed, wherein it is possible that the secondcomponent 106 forms undercuts with the microstructure. Thus a connectionof the first component 105 to the second component 106 is possible inthe region of the roughening 109 in the manner of an adhesive bond. Theroughening 109 permits a non-positive and/or positive connection of thefirst component 105 to the second component 106 which is able totransmit greater forces between the first component 105 and the drivecable 107 than might be the case if the second component 106 were tobear only against a relatively smooth surface of the first component105. A detachment of the second component 106 from the first component105 is thus prevented. Thus the coupling 108 of the drive cable 107 tothe carriage 103 is configured to be sufficiently stable in order to beretained in a reliable manner even in the event of an accident. Thus itis possible to use the drive cable 107 as a brake for the carriage 103and thus for the roof element 101.

FIG. 5 shows the arrangement 200 according to a further embodiment. Thecoupling 108 comprises a recess 110. The recess 110 is formed in aregion 118 of the first component 105 facing the drive cable 107. Therecess 110 is configured in the manner of a slot and extends over a partof the first component 105 in the X-direction. The recess 110 isconfigured such that it penetrates the region 118 in the Y-direction.

Plastics material of the second component 106 is arranged in the recess110. Additionally, a retaining head 111 is configured on one side 112 ofthe first component 105 remote from the drive cable 107. The retaininghead 111 is formed from the plastics material of the second component106.

The retaining head is arranged in a region 113 on the recess 110. Theplastics material of the second component 106 extends from the drivecable 107 through the recess 110 and forms the retaining head 11 on theside 112. The retaining head 111 has, in particular, a larger crosssection than the recess 110. Thus, by means of the retaining head 111and the material, a type of plastics rivet is formed in the recess 110,said plastics rivet reliably fastening the drive cable 107 to thecarriage 103 and/or the first component 105.

By means of the recess 110 in the first component 105, it is possible toproduce a through-injection-molding which is provided on the side 112remote from the cable 107 with the retaining head 111 made of a plasticsaccumulation, in the manner of a welding dome. By means of the plasticsmaterial in the recess 110 and on the drive cable 107, the retaininghead 111 reliably retains the second component 106 on the firstcomponent 105 such that, in the event of an accident, sufficient forcesare able to be transmitted to the drive cable 107, in particularsufficient for an EU NCAP. Thus the coupling 108 of the drive cable 107to the carriage 103 is configured to be sufficiently stable in order tobe retained reliably in the event of an accident. Thus it is possible touse the drive cable 107 as a brake for the carriage 103 and thus for theroof element 101.

FIG. 6 shows the arrangement 200 according to a further embodiment. Theembodiment of FIG. 6 substantially corresponds to the embodiment asdescribed in connection with FIG. 5. Additionally, a retaining element114 is provided.

The retaining element 114 is, for example, a sheet metal element whichis connected to the drive cable 107 so that the drive cable 107 and theretaining element 114 are immovable relative to one another. Forexample, the retaining element 114 is crimped onto the drive cable 107.The retaining element 114 extends from the drive cable 107 through therecess 110 into the retaining head 111. The retaining element 114comprises a projecting region 115. The projecting region 115 projects onthe side 112 over the first component 105. Thus an undercut and/or ahooking of the retaining element 114 behind the first component 105 ispossible.

For producing the arrangement 200, the retaining element 114 is insertedinto the recess 110, so that on the side 112 it forms the projectingregion 115. Subsequently, the drive cable 107, the retaining element 114and the first component 105 are encapsulated by injection-molding, sothat the second component 106 is formed. The retaining element 114 ispositively connected to the first component 105, for example in themanner of a bayonet closure. The retaining element 114 is clamped withthe first component 105, so that a reliable connection is made betweenthe drive cable 107 and the first component 105 by means of theretaining element 114.

The retaining element 114 comprises an extension in the X-direction.Thus the retaining element 114 contributes to the prevention of arotation and/or deflection about the Y-axis of the carriage 103, whichis articulated to the front on only one side, occurring in the event ofan accident. The rotation and/or the deflection of the carriage 103 maylead to a detachment of the second component 106 from the firstcomponent 105 and thus to a detachment of the drive cable 107 from thecarriage 103. As the rotation and/or the deflection is reduced, the riskof a detachment of the second component 106 from the first component 105is reduced. Thus the attachment of the drive cable 107 to the carriage103, in particular to the first component 105, is configured to bereliable. In particular, it is possible to transmit forces by means ofthe coupling 108 to the retaining element 114, which is required by a USNCAP. Thus the coupling 108 of the drive cable 107 to the carriage 103is configured to be sufficiently stable in order to be retained in areliable manner, even in the event of an accident. Thus it is possibleto use the drive cable 107 as a brake for the carriage 103 and,therefore, for the roof element 101.

FIG. 7 shows the arrangement 200 according to a further embodiment. Theembodiment of FIG. 7 substantially corresponds to the embodiment asdescribed in connection with FIG. 6.

In contrast to the embodiment of FIG. 6, the retaining element 114 isangled back in the projecting region 115. In the projecting region theretaining element 114 is angled-back relative to a main direction ofextension, for example bent-back. The main direction of extensionextends between the drive cable 107 and the recess 110. In the exemplaryembodiment shown, the two ends of the sheet metal element which formsthe retaining element 114 in each case are at an angle relative to themain direction of extension. According to further embodiments, only oneend is angled back. According to embodiments, the retaining element 114in the projecting region 115 is fully angled in the X-direction.According to further embodiments, the retaining element 114 in theprojecting region 115 is only partially angled in the x-direction.

By the bent-back ends in the projecting region 115, the retainingelement 114 is reliably clamped to the first component 105, so that areliable connection is made between the drive cable 107 and the firstcomponent 105 by means of the retaining element 114. By the bent-backend in the projecting region 115, the retaining element 114 is reliablyretained by the second component 106. A decoupling of the retainingelement 114 from the carriage 103 and/or the first component 105 is thusprevented. The coupling 108 of the drive cable 107 to the carriage 103is configured to be sufficiently stable in order to be retained in areliable manner, even in the event of an accident.

According to further exemplary embodiments, a combination is provided ofthe exemplary embodiment as described in connection with FIG. 4 with theexemplary embodiments as described in connection with FIGS. 5 to 7.Thus, for example, both the roughening 109 and the recess 110 with theretaining head 111 are provided in the coupling 108. According tofurther exemplary embodiments, the coupling 108 comprises both theroughening 109 and the recess 110 and the retaining element 114 and theretaining head 111.

The arrangement 200 is configured irrespective of the design of thecoupling 108 such that it may be guided in the guide rail 104 with theguide channel 116. The cross section of the guide rail 104 and/or theguide channel 116 is always the same, irrespective of whether anarrangement 200 according to FIG. 4, according to FIG. 5, according toFIG. 6 or according to FIG. 7 is used. Thus the system is of modularconfiguration. Couplings 108 of different strengths are able to beformed in the same constructional space, for example, depending on thecustomer requirements. For example, it is possible to provide a scaledsystem 300, using the same constructional space but at different costsdepending on customer requirements. Additionally, compared toconventional systems an increase in constructional space is notrequired.

The invention claimed is:
 1. The arrangement for a movable roof elementfor a motor vehicle, comprising: a carriage which is designed to beguided in a rail and to be moved relative to the rail and which has afirst component and a second component, and a drive cable, wherein thesecond component at least partially surrounds the first component andthe drive cable in order to form a coupling between the drive cable andthe carriage, wherein the coupling has a recess of the first component,a material of the second component being arranged therein, a retaininghead which is configured by means of the second component on a sideremote from the drive cable in a region of the recess, and wherein thesecond component is formed from a plastics material and the coupling isformed by encapsulating the drive cable and the first component byencapsulating with the plastics material.
 2. The arrangement accordingto claim 1, wherein the coupling further comprises: a roughening of thefirst component in order to form a bonded connection between the firstand the second component.
 3. The arrangement according to claim 1,wherein the coupling further comprises: a retaining element which isconnected to the drive cable and which, starting from the drive cable,extends through the recess.
 4. The arrangement according to claim 3,wherein the retaining element comprises a projecting region whichprojects over the first component on the side remote from the drivecable.
 5. The arrangement according to claim 4, wherein the projectingregion projects into the retaining head.
 6. The arrangement according toclaim 4, wherein the retaining element is configured to be angled backin the projecting region.
 7. The arrangement according to claim 3,wherein the retaining element is connected to the drive cable by meansof a plastic deformation.
 8. The arrangement according to claim 3,wherein the retaining element is formed from a metal.